Renegade RIMIG205I User manual

INSTRUCTION MANUALINSTRUCTION MANUAL
Read through carefully
and understand these
instructions before use
RIMIG205I
Inverter Welder
200
AMP
MIG

2
INTRODUCTION
The RIMIG205I is a Multi-Process welder that incorporates MIG and MMA welding in one unit.
Adopting the most advanced inverter technology, the RIMIG205I uses Power Inverters and PWM
technology, which works by rectifying the mains AC input voltage. The rectied input voltage is then
inverted and ltered to a smooth DC current. The smoothed DC current is then sent through power
switches (Mosphets) which convert it back to a high frequency AC voltage. The AC voltage is then stepped
down by a transformer and rectied to DC. The rectied DC is then ltered and smooth for a usable power
output for welding.
The development of inverter welding machines has massive benets which include greatly reduced size
and weight, greater power efciency, multi-process capabilities and many more. The Inverter welder’s
power source produces a much stronger and concentrated stable arc which results in better quality and
more efcient welds.
In MMA mode, this unit is a constant currant DC MMA (Arc) inverter welder. In MIG mode, this unit is a
constant voltage DC MIG (Gas and Gasless) inverter welder. The MIG series is a very efcient and robust
machine. Using advanced technology coupled with an array of adjustment controls they produce superior
MIG welds. The advanced feature of polarity adjustment allows the welders to use Gas or Gasless MIG
wire.
The small size and weight of the machine coupled with it being generator friendly makes it a perfect
candidate for those on-site jobs requiring portability.
FRONT PANEL LAYOUT
1. Overheat Light.
2. Powe light.
3. Wire Speed Control.
4. Voltage Control MIG.
Amperage Control MMA.
5. MMA/MIG Switch.
6. Negative Output.
7. Positive Output
8. Euro Torch Output
1
2
3
4
5
6
7
8

3
SAFETY WARNING
•Connect the earth cable according to standard regulation.
• Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands. It is
necessary for the operator to wear dry welding gloves while he/she performs the welding task.
• The operator should keep the work piece insulated from themselves.
• Do not switch the function modes while the machine is operating. Switching of the function modes during
welding can damage the machine. Damage caused in this manner will not be covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing
should the electrode be in contact with the work piece.
• Operators shouyld be trained or qualied.
•Wear welding helmet, anti-radiation glasses and work clothes while the welding operation is performed.
• Measures also should be taken to protect people in or near the working area.
• The welding splash may cause re. Remove all ammable material away from the working area.
• Have a re extinguisher nearby, and have a trained person ready to use it.
•Noise is generated while welding/cutting, wear approved ear protection if noise level is high.
•Consult this instruction manual.
• Contact your local dealer or supplier for further advice.
•Avoid breathing the smoke and gas generated while welding or cutting.
• Keep the working area in good ventilation.
• Wear suitable respiratory protection.
ELECTRIC SHOCK: IT CAN KILL
ARC RAYS: HARMFUL TO PEOPLE’S EYES AND SKIN.
FIRE HAZARD
NOISE: POSSIBLY HARMFUL TO PEOPLE’S HEARING.
MACHINE FAULT:
SMOKE AND GAS GENERATED WHILE WELDING OR CUTTING:
HARMFUL TO PEOPLE’S HEALTH.
Duty Cycle is a percentage of 10 minutes that the unit can weld at rated load without overheating. If unit
overheats, thermostat(s) opens, output stops and the cooling fan runs. Wait fteen minutes for unit to cool
down. Reduce amperage, or duty cycle before welding again.
DUTY CYCLE 20%
MACHINE OPERATING SAFETY
CAUTION WORKING LONGER THAN RATED DUTY CYCLE CAN DAMAGE MACHINE AND
VOID WARRANTY
WARNING IN THE PROCESS OF WELDING AND CUTTING THERE IS A POSSIBILITY OF
INJURY TO YOUR PERSON OR THOSE AROUND YOU. PROPER SAFETY EQUIPMENT MUST BE USED,
AND RELEVANT SAFETY REGULATIONS FOLLOWED TO PREVENT INJURY. PLEASE TAKE SAFETY INTO
CONSIDERATION DURING OPERATION.

4
TECHNICAL SPECIFICATIONS
ACCESSORIES
1 x 3M MB 15AK Binzel torch
1 x 4M cable with electrode holder
1 x 4M earth cable with clamp
Item Description
Product Code RIMIG205I
Rated Input Voltage AC 240V 1 Phase
Frequency (Hz) 50/60
Rated input capacity (kVA) 7.7
MIG Output Current Range 50A-200A
Output Voltage Range 16.5V-24V
MMA Output Current Range 20A-160A
Output Voltage Range 20.8V-26.4V
No-load output voltage 57V
Efciency (%) 85%
Power Factor (cos) 0.87
Load Duty Cycle 20%
Protection Class IP21S
Cooling method Fan-cooled
Wire size 0.8 / 0.9

5
Wire Speed:
In MIG mode it adjusts the wire speed and proportionately affects the amperage. The increase in
wire speed determines the amount of weld penetration. Too high of a wire speed will result in a burn
through. It is important to correlate the welding voltage and the wire speed to achieve the desired
result. It is highly recommended that you practice on a scrap piece of metal to determine what wire
speed and voltage combination is suitable for the metal to be welded. The chart below is a good
starting point of voltage and wire speed settings that can be used in relation to the welding wire
diameter.
MIG Voltage & MMA Amperage:
In MMA mode you can adjust the output amperage. In MIG mode it adjusts the welding voltage
which determines the width and height of the bead. Turning the knob clockwise increases the
welding voltage. There is a correlation between the welding voltage and the arc length. A short
arc length will decrease the voltage which will result in a narrow, "ropey" bead. A longer arc length
(obtained by increasing the voltage) will produce a more at and wider bead. An excessive arc length
will yield an incredibly at bead or an undercutting of the weld metal. It is highly recommended that
you practice on a scrap piece of metal to determine what voltage is suitable for the metal to be
welded.
SETTING THE MACHINE UP
KNOB FUNCTIONS
AC 240V

6
INSTALLATION & OPERATION OF MIG
1. Turn the mode selector switch to MIG and the function switch to MIG TORCH.
2. If using gas assisted (solid) wire, turn the mode selector to "standard". Connect the gas bottle with the ow
meter and a gas hose to the back of the machine, secure the gas bottle so it cannot fall over.
3. MIG welding with:
A) SOLID WIRE: Insert the earth cable quick connector (jack plug) into the negative dinse socket output
in the front panel and the clamp on to the work piece. Insert the MIG quick connector (jack plug) into the
positive dinse socket output in the front panel.
B) GASLESS WIRE: Change the polarity on the selector front panel located on front panel. Always ensure
that the polarity is changed back for welding with Gas.
4. Fit the MIG wire on to the spool adaptor and ensure wire direction is a clockwise rotation to feed the wire
out.
5. Choose drive roll and contact tip appropriate to your wire size.
6. Loosen the pressure wheel, t wire through the spring inlet guide over drive roll and through the outlet
guide, close the pressure wheel and adjust pressure so wire feeds through but can slip if wire gets jammed.
7. Fit the wire into the torch by hand and then tighten the torch on to the euro output socket.
8. Press the trigger button to feed wire to end of torch tip. Weld with a distance/stick out of about 10 times the
wire thickness.
• Open the valve of the gas cylinder and adjust the ow rate to 10 to 15 LPM (Litres per Minute).
• Adjust the voltage, choke and wire speed (amperage) knob to the correct settings based on the thickness of
the work piece and wire diameter.
• Press the torch switch to feed out the wire and gas and begin to work.
The machine is equipped with a power voltage regulator. When power voltage moves between ± 10 % of
rated voltage, it will still work normally.
Should an extension cable be required (not recommended), a cord gauge of not less than 2.5mm is
suggested and not longer than 10 meters.
To prevent the cooling system malfunctioning, make sure the fan intake of the machine is not covered or
blocked

7
1. Turn the mode selector switch to MMA
2. The electrode holder and earth clamp are easily connected to the machine by inserting the quick connector
and twisting it clockwise. Always ensure a tight t.
3. Generally, Reverse Polarity is used in which the welder’s electrode holder will be connected in the “+”
Positive Terminal while the earth clamp is in the “- “Negative Terminal. The welder does have the ability to
be used for Straight Polarity or Reverse Polarity. We recommend you connect the polarity in accordance
with the Electrode Manufacturers recommendations. If the polarity is connected incorrectly it will cause an
unstable arc, spatter, and/or the electrode to stick. If these symptoms occur change the polarity.
4. Set the amperage knob according to type and size of welding rod being used and the arc force to the
desired penetration required.
INSTALLATION & OPERATION OF MMA

8
TYPICAL MIG PROCESS SETTINGS
NOTE These settings are guidelines only. Material and wire type, joint design, setup position,
shielding gas, etc. affect settings. Test welds to be sure they comply with specications.
Material thickness
determines weld
parameters
Select wire size
Wire size:
Recommended
Wire Speed
(Approx.)
Select Voltage
Convert material thickness to Amperage (A)
(0.024mm = 1 Ampere)
3mm = 125 A
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Set voltage midway between high/low voltage
Wire Speed (amperage) controls weld penetration
(Wire speed = burn-off rate)
Voltage controls height and width of weld bead
Wire size Amperage range Gas L/min
0.8mm 40 - 154A 10
0.9mm 50 - 180A 10 - 15
1.0mm 60 - 270A 15 - 25
Select wire size
(Amperage)
125A based on 3mm
material thickness
M/pm meters per
minute
0.6mm 88mm per ampere 11m/min
0.8mm 50mm per ampere 6.3m/min
1.0mm 40mm per ampere 5.0m/min

9

10
WARNING
•This machine is mainly used in the welding industry. It will produce Electric & Magnetic fields, so the
operator should ensure proper protection or screening is used.
•Earth leakage-circuit breaker should be used with this machine!!!
•During welding, DO NOT pull out or insert any plugs or cables, it can lead to life-threatening danger
and cause damage to the machine.
•Before connecting cables make sure the power is off. The correct way is to connect the cables to
the machine first, and make sure they are firmly tightened and then connect the power plug to the
power source.
MAINTENANCE
WARNING Before maintenance and checking, power must be turned off, Before
opening the cover disconnect the machine from electricity!
1. Remove dust with dry, clean compressed air regularly. If the welding machine is operated in an area where
the air is polluted with smoke and dust, the machine needs to be cleaned regularly. Remove dust monthly.
2. Pressure of compressed air must not be more than 5 bars in order to prevent damage to small components
inside the machine.
3. Check inside the welding machine regularly and make sure the output terminals are connected tightly and
connectors are not damaged. If burnt, loose or damaged please tighten or replace if necessary. Beware of
moving part.
4. Avoid water and steam entering the machine, if the welding machine does get wet, dry inside the machine
and check the insulation of machine.
5. If the welding machine will not be operated for long periods it should be put into a box or covered and stored
in a cool dry area.
TORCH & WIRE FEED SET UP FOR
ALUMINIUM WIRE
1. Lay the torch out at on the ground and remove the front-end parts.
2. Remove the liner retaining nut.
3. Carefully pull the liner out of the torch cable assembly.
4. Carefully unravel the new liner.
5. Carefully feed in the Teon liner in short forward movements down the torch lead all the way to exit the
torch neck. Be careful not to kink the liner.
6. Replace the front-end parts.
7. Fit the liner collet, liner O-ring and liner retaining nut.
8. Push the liner rmly into the torch lead and tighten the liner retaining nut.
9. Cut the liner ush with the end of liner retaining nut using a sharp box cutter knife.
10. Connect the torch to the machine tighten and secure the torch euro connector to the machine euro
connection.
11. Install a U groove drive roller of the correct size for the diameter wire being used.
12. Place aluminium wire onto spool holder. Feed the wire through the inlet guide tube on to the drive roller.
13. Press and hold the inch wire button to feed the wire down the torch cable through to the torch head.
14. Fit an Aluminium contact tip of the correct size to match the wire diameter being used.
15. Fit the remaining front-end parts to the torch neck ready for welding.

11
OPERATING PRECAUTIONS
1. OPERATING ENVIRONMENT
• The machine can perform in environments where conditions are dry with a max humidity of 60%.
• Ambient temperature should be between -10 to +40 degrees celsius.
• Avoid operating machine in direct sunshine, rain, or snow.
• Avoid operating the machine in environments where there is pollution or high concentrations of dust or
corrosiveness gas in the air.
2. PROPER VENTILATION
All users must ensure proper ventilation of the welder. The welder is powerful and compact which generates
high currents and heat. Wind alone cannot ensure proper cooling, so it is advisable to place a fan to cool
down the machine during hot weather or continuous usage in order to keep the components working for a
long shelf life. Make sure the machines vents or built-in fans are not blocked or covered and it’s receiving
proper ventilation. Keep the welder at a minimum of 30cm from any objects to ensure proper ventilation.
3. AVOID OVER VOLTAGE
The specic power voltage can be found in the main technical specication chart listed above or on the rear
plate of the machine. The automatic voltage compensation circuit will ensure that the welding current is
functioning in the correct range. If the power voltage is exceeded from the max allowed value, it will damage
the components of the machine.
4. AVOID OVERLOADING
Limit the welding current strictly to the max allowable duty cycle. Do not exceed the max load because
overloading can damage and burn up the machine.
5. DUTY CYCLE
Duty cycle refers to the percentage of the working time against a 10-minute work cycle. For example, if the
welder has a 20% duty cycle at 240A this means you can run the welder at 250A for 2 min in a 10 min
work cycle. The remaining 7 minutes will be needed to let the machine cool down. If the welding current
decreases, the duty cycle will increase and vice versa.
Do not operate over the recommended duty cycle of the welding machines or damage will occur to the
machine that is irreversible. When output exceeds the duty cycle limit, the temperature within the welding
machine will rise and the protective circuit will cut off the power source output. The power output will then
resume operation only when the equipment has cooled down to normal temperature.
Note: Continuous overload operation will damage the welding power source. In these cases, the damage is not
covered by warranty repair.
WARNING This machine produces an electromagnetic field during operation. This
field may under some circumstances interfere with active or passive medical implants. To reduce
the risk of serious or fatal injury, we recommend persons with medical implants to consult their
physician and the medical implant manufacturer before operating this machine.

12
DAILY CHECKING
The following can cause problems with welding: Fittings, welding materials, environmental factors, power
supply and welding techniques. User must try to improve working conditions.
Position Checking keys Remarks
Control panel 1. Condition of switches and potentiometers.
2. Warning lights Replace if faulty.
Cooling fan 1. Check if there is air ow.
2. Abnormal vibration or noise.
Check for obstructions at fan intake or broken
blades.
Powered ON 1. Any burnt smell.
2. LED working. Check fault nding.
Periphery
1. Check gas pipe not leaking or kinked.
2. Check housing and other xed parts are
tight and or damaged
Correct any faults.
Pressing arm 1. Check that it is not over tightened and is not
melted / distorted Leeds to wire slipping.
Wire inlet &
outlet
guide Tube
1. Check that there is no buildup of steel dust
in the tube (residue)
2. Wire diameter and the tube inner diameter
match
3 .Check that the tube lines up with the center
of the drive roll slot
Clean the residue check the cause and solve it.
If mismatch, lead to unstable arc and residue build
up.
If unaligned, leads to unstable arc and residue build
up.
Drive Roll 1. Drive roll matches the wire size.
2. Check that slot is not blocked up
1. Leeds to unstable arc and the wire slipping or
deforming.
2. Replace if worn out.
Pressure wheel 1. Check the stability of its movement, and
wearing-out of pressure wheel(bearing) Lead to unstable arc and wire slipping.
Nozzle/ Shroud 1. If distorted or damaged
2. Splatter built up.
Replace. Can cause porosity. (use anti splatter
spray)
Contact Tip 1. Hole in tip oval worn out.
2. Hole blocked or wire welded on to tip
Replace - unstable and broken arc Replace - reason
worn tip, voltage to high, rusted or dirty wire.
Wire Liner
1. Check the liner is the correct length.
2. Check wire diameter and the liner inner
diameter are correct
3. Partial unwinding and stretching
4. Blocked caused by rust and dust in the tube,
and llings of the wire copper coating.
5. Liner broken or bent.
Must touch tip - Replace if too short will cause the
arc to be unstable. Reason of unstable arc, use the
correct liner.
Result in poor wire feeding and unstable arc,
Replace
Tip Adaptor 1. Threads damaged or distorted
2. Holes blocked
Replace can damage contact tip or swan neck and
cause unstable and broken arc, porosity in weld
Torch cable
1. Check that torch cable isn't coiled or kinked
2. Check the Euro adaptor connector on the
torch is tight
Cause poor wire feeding
Unstable arc if cable coiled or kinked.
Output cable
1. Wearing-out of the cable insulated material.
2. Cable jack plug connector exposed or loose
3. Earth clamp not damaged or burnt, lug
tightened
Loose or bad connections get very hot causing a
drop in welding amperage
240v Input cable
1. Check the cable between the plug and the
machine
2. Plug is in good condition
Replace damaged plugs with correct amperage plug
WELDING MACHINEWIRE FEEDING ASSEMBALYMIG TORCHCABLE

13
TROUBLESHOOTING
WARNING Experimentation and careless maintenance may lead to more problems to
the machine. This will make formal diagnostic and repair more difficult. When the machine is open
there may be exposed connections containing life-threatening voltages. Any direct or indirect touch
will cause electric shock, and severe electric shock will lead to death.
If the machine fails to work after maintenance and checks, please contact your local distributor or
our after-sale service center.
DO NOT REPAIR OR MODIFY MACHINE IF STILL UNDER WARRANTY
Faults Description
Power
indicator is
not lit, fan
does not
work and
no welding
output
1. Make sure power switch is working.
2. Check if the plug point you are using is working.
3. Some of heat-variable resistors (four) of power board are damaged, when that happen,
general DC24V relay is open or connectors have poor contact.
4. Power board (bottom board) is damaged, DC310V voltage cannot be sent to the top
board.
a) Silicon Bridge is broken or connector of Silicon Bridge has poor contact.
b) Power board has been burnt.
c) Check connections from ON switch to power board are in good condition, check continuity
of ON OFF switch.
d) Check cable from power board to MOS board (top board) are connected properly.
5. Auxiliary power of control board is faulty.
Power
indicator is
lit, fan works,
no welding
output
1. Check if all cables are connected properly.
2. Output connector is disconnected or damaged.
3. Control cable or switch of torch is broken.
4. Control circuit is damaged.
5. Is correct welding process selected?
6. Is the MIG jack plug connected?
Power
indicator is
lit, fan works,
and abnormal
indicator
is lit.
1. Can be in overheat protection; wait for 15 minutes.
2. Maybe it is overcurrent protection, turn machine off for 30 seconds then switch on again.
If still not working there is a fault on the MOS board.
3. Maybe inverter circuit is in fault, please unplug the supply power plug of main transformer
which is on MOS board (insert which is near the fan) then switch the machine on again.
3.1 -If abnormal indicator is still lit, some of eld mosfets of MOS board is damaged, test
each
one the odd one out mast be replaced with the same specications.
3.2 -If abnormal indicator is not lit,:
•Transformer of middle board is damaged. or
•Secondary rectier of transformer board is damaged, nd faulty rectier and
replace with same specications.
Output
Current is not
stabilized
1. Supply voltage is not stable.
2. There is harmful interference from supply voltage or other equipment.
3. Bad connections - Hot/bad connections or points on earth cable or electrode holder can
cause current to drop or be unstable.
There is
porosity in
the weld (air
holes)
This happens if not enough shielding gas is supplied around the weld or foreigner gasses/
air enter the weld:
1. Check that the gas supply is owing sufciently out the torch.
2. Clean surface of welding material of oils, stain, rust, lacquer or other impurity.
3. Wrong shielding gas is being used or contaminated gas.

14
PARTS DIAGRAM

15
PARTS LIST
Ref. Description
1 Handle
2 Plastic Hinge
3 Control Pcb Board
4 Plate
5 Wire Feeder Inching Buttom
6 Beam
7 Hight-Side Casing
8 Cable Connector
9 Wire Feeder
10 Protective Ring
11 Middle Casing
12 Plastic Panel
13 Indicator
14 Reactor
15 Switch
16 Potentiometer
17 Euro-Type Sockets
18 Latch Catch
19 Foot Pad
20 Bottom Casing
21 Left-Side Casing
22 Grounding Screw
23 Fan
24 Fan Cover
25 Switch
26 Power Cable
27 Magnetic Valve
28 Main Control Pcb Board
29 Pcb Fittings
30 Main Transformer
31 Rectier Device
32 Igbt Radiator
33 Capacitor
34 Rectier Silicon Bridge

TradeTools Pty Ltd
131 Quinns Hill Rd East
Stapylton, Queensland 4207
P. 07 55406400
www.tradetools.com